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Manufacturing variation effects on the fit and function of a finished product, e.g., a vehicle, can be analyzed into designs using 3D dimensional simulation method. In an effort to reduce the predicted process variation for improving the dimensional quality during design phase, an integrated analytical approach is presented using robust design and variation simulation method that leads to select the optimal product datum and locating schemes for the process design. The Taguchi’s robust design and ANOVA (analysis of variance) are used in the algorithm to generate meaningful information about the effects of several processes simultaneously on the variability of the measured products. The application of the proposed method in process control with the dynamic factor, such as powertrain roll, is also discussed.